101602-2492 ZEXEL 9 400 614 776 BOSCH INJECTION-PUMP ASSEMBLY 9400614776 1016022492 220203651b

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 614 776 9400614776

ZEXEL 101602-2492 1016022492

HINO 220203651B 220203651b

Service parts 101602-2492 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-9940

3. GOVERNOR 105400-6221

4. SUPPLY PUMP 105220-5140

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156636-4821

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-4230

11. Nozzle and Holder 23600-1580

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105041-5030

14. NOZZLE 105015-5160

15. NOZZLE SET

Include in #1:

101602-2492 as INJECTION-PUMP ASSEMBLY

Include in #2:

104234-2004 as _

Cross reference number

BOSCH 9 400 614 776 9400614776

ZEXEL 101602-2492 1016022492

HINO 220203651B 220203651b

Zexel num

Bosch num

Firm num

Name

101602-2492

9 400 614 776

220203651B HINO

INJECTION-PUMP ASSEMBLY
W06D K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8140

Bosch type code EF8511/9A

Nozzle 105780-0000

Bosch type code DN12SD12T

Nozzle holder 105780-2080

Bosch type code EF8511/9

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600

Overflow valve 131424-5720

Overflow valve opening pressure kPa 255 221 289

Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95

Tester oil delivery pressure kPa 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-4-2-6- 3-5

Pre-stroke mm 3.1 3.05 3.15

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 9.5

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 45.6 43.6 47.6

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point B

Rack position 9.7

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 43.7 40.7 46.7

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_03

Adjusting point -

Rack position 7.8+-0.5

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 9 7.5 10.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_04

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 63 63 73

Fixing the lever *

Rack limit *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Set idle sub-spring
----------
K=11
----------

Speed control lever angle

F:Full speed I:Idle (1)Set the speed at aa, set the stopper bolt (2)Set the pump speed at bb. (3)Stopper bolt setting
----------
aa=900r/min bb=750r/min
----------
a=(2deg)+-5deg b=(15deg)+-5deg c=(5deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Distance from normal side pin = aa. (2)At shipping: rack position = bb or less, speed = cc. (3)Contacts normal side pin
----------
aa=2.5+-0.5mm bb=6.9mm cc=0r/min
----------
a=27deg+-5deg b=53deg+-5deg c=(6deg)

Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(70deg)